Method and apparatus for conducting gaseous reactions in the presence of solid particles



Oct. 25, 1949. E. UTI'ERBACK 2,486,229

7 IETHOD AND APPARATUS FOR CONDUCTING GA SBOUS REACTIONS IN THE PRESENCE OF SOLID PARTICLES Original Filed April 20, 1944 I 2 Sheets-Sheet 1 r 5g if uxpkomkaou INVENTOR I 46 ERNEST uTTERanc/r giaw? A NTon AT'I'ORNE Oct. 25, 1949. E. UTTERBACK 2,486,229

METHOD AND APPARATUS FOR CONDUCTING GASEOUS REACTIONS IN THE PRESENCE OF SOLID PARTICLES Original Filed April 20, 1944 2 Sheets-Sheet 2 INVENTOR r ffiwfsr UTTERBHC/f ENT on ATTORNE Patented Oct. 25, 1949 METHOD AND APPARATUS FOR CONDUCT- ING GASEOUS REACTIONS IN THE PRES- ENCE OF SOLID PARTICLES Ernest Utterback, Jackson Heights, N. Y., as-

signor to /Sooony-Vacuum Oil Company, Incorporated,

Original application An 1946, Serial No. 679,728

13 Claims. 1

This application is a division of my application Serial Number 531924 filed in the United States Patent Ofllce on April 20. 1944. now United States Patent 2,425.969, issued August 19, 1947.

This invention has to do with a method and apparatus for conducting gaseous conversions in the presence of a moving particle form solid contact mass material which may or may not be catalytic in characterr Exemplary of such processes is the catalytic hydrogenation dehydrogenation, desulfurization, reforming, polymerization, alkylation or cracking of hydrocarbons. Typical is the cracking conversion of hydrocarbons, it being well known that gas oils boiling between approximately 500 F. and 750 F. may be substantially cracked to gasoline, gas and heavier products by passing them at reaction conditions of temperature and pressure such as, for example, temperatures of the order of 875 F. at pressures somewhat above atmospheric in contact with a solid adsorptive catalytic contact mass. Usually such contact masses partake of the nature of natural or treated clays such as fullers earth or SuperfiltroY which is a treated natural silica-alumina clay or of synthetic associations of alumina, silica or alumina and silica, any of which may have other constituents added such as certain metallic oxides.

impairing its catalytic eiliciency. This necessitates periodic regeneration of the catalytic material. Recently the process has been developed as one in which the particle form solid contact mass material is moved cyclically through two zones in the first of which it is subjected to gaseous conversion and in the second of which it is subjected to the action of a fluid regeneration medium, such as a combustion supporting gas, acting to burn oil contaminant material deposited upon the contact mass during conversion. Such cyclic systems in which the solid material is continuousl moving, when used for many reactions, such as the cracking conversion of hydrocarbon vapors, have been found to offer many advantages over the older type systems wherein an in situ catalytic material was subjected to alternate conversion and regeneration reactions. These advantages need not be dealt with herein, as the present commercial success of the moving solidtype systems bears out the statement. When the particle form solid catalytic material to be employed is of a particle sizelarger than a pulverized powder, it has been found desirable to conduct such material through During the conversion reaction certain cokey materials maybe deposited upon the catalytic material thereby a corporation oi New York rll 20, 1944, Serial No. Divided and this application June 2'1,

the conversion andregeneration zones as sub-- stantially compact columns of moving particle form material. Such systems are part cula y desirable in order to limit the rate of attrition of the particle form catalytic material and the erosion of the equipment. Commercially the regeneration and conversion reactions are conducted in separate vessels having auxiliary solid feed and discharge chambers, and suitable externally located solid material conveyors are proglided to complete the solid material cyclic sys- In the case of catalytic cracking of hydrocarbon oils, the overall reaction has been found to be endothermic requiring the supply of a considerable quantity of heat, whereas in the case of the catalyst regeneration by combustion of deposited contaminant therefrom the overall reaction is exothermic resulting in the liberation of considerable quantities of heat. Present practice is to supply the heat for the endothermic conversion either by superheating the hydrocarbon charge to the conversion zone to a temperature somewhat above the desired average conversion temperature or by provision of heat transfer tubes within the through which tubes an externally heated heat transfer fluid is circulated. Since the quantity of heat liberated in the contaminant combustion reaction is generally sufllcient, if not removed, to heat the solid catalytic material to temperatures at which the catalytic activity of the material would be permanently impaired, it has also been a practice to remove this heat by means of an externally cooled heat exchange fluid passed through heat transfer tubes placed within the regeneration zone or between small regeneration stages. The necessity for the provision of such heat transfer tubes and auxiliary external heat transfer fluid circulation systems greatly adds to the complexity and cost of the apparatus required for such reactions. It has been found, however, that properly designed cyclic conversion units wherein the solid passes through the conversion and regeneration vessels and wherein such auxiliary heat transfer systems are employed are reasonably economical as regards construction and operation when built in large sizes, for example, of 10,000 barrels per day feed stock capacity (measured as liquid 42 gallon barrels). However, when the size of such units is reduced to say 1000 to 4000 barrels per day capacity, the reduction in capital cost is considerably less than that of the capacity. This latter diiliculty is even more markedly noticeable in catalytic conversion zone conversion units of other types, and as a result. there is a pressing need for a reasonably inexpensive and simple hydrocarbon conversion process and apparatus suitable for small petroleum refineries.

The present invention is specifically directed toward such a method and apparatus wherein a particle form solid contact mass is cyclically passed as substantially compact columns through conversion and regeneration zones.

A major object of this invention is the provision of a simple, compact inexpensive apparatus for conversion of hydrocarbons in the presence of a substantially compact column of moving particle form solid con-tact material, which apparatus is adapted to the requirements of small refineries.

Another object of this invention is the provision of a method and apparatus for conducting endothermic and exothermic reactions in the presence of a moving particle form solid material wherein the heat liberated by the exothermic reaction is made available for the endothermic reaction without the use of tubes for fluid heat transfer medium flow within the reaction zones.

Another object of the invention is the provision, within an operation wherein a moving particle form solid contact mass material is cyclically passed through endothermic and exothermic reaction zones in heat exchange relationship with each other, of a simple method for thermally balancing the two opposite thermochemical reactions.

Still another object of the invention is the provision of an apparatus for catalytic hydrocarbon conversion or treatment wherein within a single vessel a particle form solid catalytic materia1 may be passed cyclically through a hydrocarbon conversion zone and a catalyst regeneration zone, said zones being in heat exchange relationship with each other.

Another object of this invention is the provision of an apparatus for catalytic hydrocarbon conversion which may be readily tied in with existing thermal cracking stock preparation and product fractionation equipment.

Another obi ect of the invention is the provision within an apparatus of the type above described of a conveyor construction particularly adapted to convey said solid material between zones as a substantially compact column of solid material without excessive attrition of said solid material.

Still another object of the invention is the provision in an apparatus of the type above described of a novel device for admitting and distributing vapors to the conversion or regeneration zones.

These and other objects of this invention will become apparent from the following description of this invention.

In order to better understand this invention reference should now be made to the attached drawings of which Figure 1 is an elevational view, partially in section of a typical form of the apparatus of this invention, Figure 2 is a plan view of this apparatus taken at line 2-2 of Figure 1.

Figure 3 is a detailed enlarged view of a. vapor distributing device used in this apparatus and Figure 4 is a detailed view of part of one of the conveyors used in this apparatus showing the special construction thereof. All of these drawings are highly diagrammatic in character.

Turning now to Figure 1, we flnd a vertical cylindrical vessel Ill closed on its upper end by a rounded top H and reduced in diameter at its lower end so as to terminate in the reduced hottom section l2. A horizontally extending partition i1 is supported across the vessel near the upper end thereof, thereby providing chamber it suitable for confining a bed of particle form solid material. Depending from said partition are a plurality of uniformly distributed pipes II which terminate within the lower end of said vessel. These pipes provide confined vertical passageways for solid material flow from the chamber 34 to the restricted bottom section l2 of the vessel and at the same time comprise the regeneration zone. These tubes may be provided with internal or external fins to aid heat transfer between the regeneration zone formed thereby and the hereinafter described adjacent conversion zone. Extending centrally through the vessel i0 is the vertical conveyor casing ii. A plurality of horizontal apertures 66 are provided in this casing near its lower end for admittance of solid material thereinto. A number of vertically spaced discharge ports I0, II are provided on the casing at levels below the partition I I for discharge of solid material into the space provided within said vessel It! not occupied by the pipes IS, the upper portion of said space comprising the conversion zone as will be hereinafter shown. A screw type conveyor comprising a central drive shaft 82 and a special spiral flange 65 attached along most of the length thereof is provided within the casing l3. This conveyor will be further described hereinafter. The conveyor drive shaft 82 extends through the top of the vessel through the stuiilng box 3| and is connected by a gear arrangement 20 to drive motor 28. Downwardly sloping converging partitions l8 and 11 are positioned across the annular space within the vessel l0 shortly above the lower ends of the pipes I6 thereby partitioning the zone 35 from the bottom section I2 of the vessel. Conveyor casings l4 and I5 extend upwardly from this latter partitioning to a level within the chamber 34. These casings are also provided with apertures such as aperture I00 near the lower ends thereof for admittance of solid material, and the casings are open on their upper ends to permitdischarge of solid material into chamber 34. These casings are braced within the vessel by partition I1. Screw conveyors, similar to the one within casing l3 are provided within each of said casings and the drive shafts 8| and 83 thereof extend through stufllng boxes 30 and 32 in the top of the vessel. These drive shafts are driven through gear arrangements 2'! and 28 by motors 24 and 25, respectively. The drive motors on all of the conveyors are of an adjustable speed type for reasons to be explained hereinafter. In place of variable speed motors, constant speed motors connected through adjustable speed drive mechanisms to the conveyor shafts may also be used. As will be hereinafter shown, the conveyor systems described, provide for the cyclic flow of particle form solid material through the regeneration and conversion zones which zones are in heat exchange relationship with each other.

Extending across the annular space between shell in and casing is at levels above the partitions 16 and H are the vertically spaced partitions ll and 42. A plurality of uniformly spaced holes are provided through each of said partitions and covering each of said holes is a hollow. louvered truncated cone 43 on partition 42 and cone I4 on partition l I. Dependent from the top of each cone is a short pipe 44 which extends downwardly through the hole in the partition and terminates therebelow. The pipes 44 and I3 of substantially space 15 provided directly below the converging partitions l and I1 and a flue gas outlet conduit I0 is provided at the top of chamber 34. Within.

the lower end of the vessel below the ends of pipes I5, are the vertically spaced horizontal partitions 52, 53 and 64 which have a plurality of properly spaced orifices therein. The orifices in these partitions are so arranged as to divide the solid material flow from the bed, of solid material below pipes I6 into a plurality of uniformly distributed streams which are gradually and proportionately combined into relatively few streams flowing into the restricted bottom section I2, from the bottom of which section the solid material passes into conveyor casing I3. This partition and Orifice arrangement provides uniform withdrawal of the solid material from the entire crosssection of the bed IOI below pipes I5, thereby'insuring a substantially uniform rate of downward solid flow in all of the pipes I6. Within the section I2 are a number of uniformly spaced vertical cooling tubes 49 connected between headers 50 and 5|, which, in turn, connect through manlfolds 52 and 53 and pipes 54 and 55, respectively, into the vertical drum 56. This drum is pro vided at its bottom with an inlet pipe 60- for cooling fluid, such as boiler feed water and at its upper end with an outlet pipe 51 for vapor such as steam. A pressure control valve 58 is provided on the steam outlet pipe 51, and a liquid level control mechanism 59, operating the diaphragm valve 6| on inlet pipe 60 is provided to permit control of the water level both within the drum 5G and within the vertical pipes 49. This arrangement provides a means to control the rate of cooling of the solid material within section I2 by simple control of the liquid level in the cooling tubes 49, and permits recovery of the heat removed from the solid material as steam at the desired pressure. It will be apparent that suitable volatile liquids other than water may be used in this apparatus, if desired. Finally, a pipe 22' with valve 23 thereon is provided to permit initial filling of the vessel I0 with particle form solid material and to permit periodic additions of makeup solid said makeup being necessitated by gradual loss of small quantities of fine mesh solid material from the vessel. Likewise pipe 41 with valve 48 thereon is provided at the bottom of the vessel to permit draining the solid material therefrom when desired. It will be understood that the pipes 22 and 41 are not-used during the normal cyclic operation of the apparatus except periodically for the purposes above stated.

Considering now the operation, the apparatus is first filled with particle form solid material roughly to the levels shown in Figure l. The solid material passes downwardly from the chamber 34 as substantially compact columns through the regeneration zone pipes I6 discharging from 7 smaller diameter than said holes in the partitions, leaving an annular space -ror gas flow therebetween. The arrangements the lower ends thereof onto bed "I, from which I it passes through the orifices in the flOW'dlS-rtributing partitions :52, 03 and. into the bottom section I2. The solid material then passes from the section I2 into the conveyor casing I3 through "apertures 05 therein and is conveyed upwardly as a substantially compact column to be discharged into the conversion zone 35 above the surface of the bed or column of said solid material therein. The height of the bed of solid material within zone 35 may be controlled by opening the ports II or 10in the casing II at the desired level. The discharge ports'are of sufllcient size as to permit discharge of theentire solid material flow substantially at the level of any set of said ports opened. By this provision the hydrocarbon space velocity (volume charge per hour per volume of solid materialuwithin conversion zone) may be varied without change in the rate of hydrocarbon throughput thus avoiding upsetting the operation of the product recovery system. The solid material then passes downwardly through the conversion zone 35' and throughthe pipes 44 extending through partition 42 into the purging zone I04 and then through pipes 13 extending through partition 4I into the seal gas zone I02. The solid material then passes into the conveyor casings I4 and I5 and is conveyed upwardly therethrough and discharged within the chamber 34 thus completin its cycle of travel.

Combustion supporting gas, such asair, is in troduced through conduit into the distributing space I5 at rates sumcient to support combustion of the amount of contaminant that is to be burned from the solid material passing through the regeneration zone. The combustion supporting gas enters the lower end of the pipes I6 and passes upwardly therethrough countercurrently to the solid material flow. Spent regeneration gas or flue gas disengages from the solid material bed in chamber 34 and is withdrawn from the top of said chamber through conduit I9. Hydrocarbon vapors heated to the desired conversion temperature in apparatus (not shown) enter through conduit 38 into vapor distributing space 45 and then pass upwardly through the distributing arrangement associated with partition 42. The flow through this distributing arrangement will be described in detail hereinafter. The vapors then pass upwardly through the downwardly flowing column of solid material in zone and disengage from the solid material at the surface 69. The disengaged conversion vapors are then withdrawn through conduit I8. Inert seal and purging gas such as steam or flue gas, is admitted to the distributing space below partition 4|. Part of this gas passes upwardly t rough the annular space between pipes I3 and the holes in the partition 4| and then through louvered truncated cones into the bed of solid material I04 between partitions 4I and 42. This inert gas passes through the bed I04, stripping the hydrocarbon vapors therefrom and then passes along with the hydrocarbon charge through the conversion zone. Another fraction of the inert gas entering space 46 passes downwardly through the bed of solid material I02 and then upwardly through the conveyor casing I4 and I5, finally mingling with the eflluent gases from the regeneration zone in chamber 34. The final frac-' tion of the inert gas entersthrough inlet vents 12 into the intermediate section of the conveyor casing it and passes upwardly and downwardly therethrough.

The rate of admittance of inert gas to space It is controlled by diaphragm valve 40 on the inlet conduit 31. said valve being actuated by the diii'erential pressure control device I! in such a way that the inert gas pressure in space 46 is constantly maintained a ilxed amount above the aseous pressure in the hydrocarbon distributing space 45 thereabove. Moreover, the gaseous pressure in chamber 34 is controlled a fixed amount below that in space 46 by means of throttling valve on the flue gas outlet conduit ii, which valve is actuated by the differential pressure control device 2|. ically provides a seal gas pressure within the central portion of the conveyor casing l3 above that at either end thereof. By the above described pressure control provisions, the interilow of regeneration gas or hydrocarbon vapors between regeneration and conversion zones is not only prevented by the substantially compact columns of solid material in the conveyor casings l3, l4 and I5, acting as seal legs, but by a positive maintenance throughout said casings of an inert gas atmosphere. Although the direction of gas flow through the regeneration and conversion zones, as shown, is preferable because it provides more uniform temperature control throughout these zones in hydrocarbon conversion systems, nevertheless satisfactory operation may be obtained in many cases where the direction of hydrocarbon flow through the conversion zone and that of the regeneration gas throu h the regeneration zone is reversed. Moreover, the invention is not to be limited by the particular gas distributing and gas collecting provisions shown herein; other conventional gas distributor and collector structure may be substituted, if desired. For example, gas distributors and collectors may be arranged within the regeneration and conversion zones to provide other than vertical flow of the gases therethrough. As will be hereinafter shown, however, the distributing arrangement shown is preferable and particularly well adapted to an apparatus of this type. Other arrangements for maintaining seal gas atmosphere within the conveyor casings may also be provided in place of that shown.

As may be seen from the above description of the apparatus, the conversion and regeneration zones are in heat exchange relationship with each other throughout a substantial portion of their lengths. Thus'the heat liberated by combustion of contaminant deposit from the solid material passing through the regeneration zone is transferred through the pipes IE to the solid material passing through the conversion zone thereby providing heat for the endothermic hydrocarbon conversion reaction conducted within said zone. Obviously an exact heat balance between the conversion reaction and the contaminant combustion reaction may not be obtained for every given set of conversion conditions. The heat required by the conversion reaction may be greater than that liberated by the contaminant conversion or the reverse may be and most often is true in hydrocarbon conversion systems. Thus, for a given set condition of conversion in the conversion zone and for a. given set rate. of contact material cyclic flow a small amount of heat liberated by contaminant combustion may remain in excess of that required for the conversion of hydrocarbons. In order to prevent a gradual This arrangement also automatrise in the temperature of the entire cyclic system, this heat should be removed. and the provision or the vertical cooling tubes 49 in the bottom section of the vessel II will accomplish this heat removal. As has been shown, the rate 0! heat removal by these tubes may be easily and accurately controlled by control of the level of volatile liquid heat transfer fluid within said tubes. It will be apparent that the heat removing load has been greatly reduced by the present apparatus design so that the total amount of coolin surface required is only a small fraction of that required in conventional conversion systems. Moreover, since most of the contaminant combustion is removed by' heat exchange with the conversion zone, the contact material will not rise to destructive temperatures, while passing through the regeneration zone. Thus, by elimination of the necessity for cooling tubes within the regeneration zone, advantage may be taken of the higher temperature differentials provided by heat transfer fluids maintained at relatively low temperature levels. This, in turn, further reduces the total amount of cooling tubes required. Also since the solid material cooling may be all accomplished at one location instead of at a plurality of stages, as in recently developed multi-stage kilns, a further simplification both in construction and in operation of the cooling system results.

By a novel method of operation, now to be described, the necessity for cooling tubes 4! may be entirely eliminated. It has been experimentally found that for any given set condition of temperature, pressure and hydrocarbon charge rate and catalyst to hydrocarbon charge ratio (pounds of catalyst passed through the conversion Charge to the Convemon zone #Ihr' Catalyst to 410 E P Contaminant Hydrocarbon Deposited Upon Gas on Charge Yield #lhr 08mm Hym catalyst Ratio, cuiated as lbs. carbon Carbon/hr.

In all of the above examples the conversion temperature, pressure and hydrocarbon charge rate were constant. Since the amount of gasoline formed in the conversion reaction is a direct measure of the amount of endothermic heat absorbed by the conversion and since the amount of contaminant deposited by said conversion is a direct measurement of the amount of heat which will be liberated by its combustion in the regeneration zone, it may be seen that'by simply varying the cyclic rate of travel of the solid catalytic material in the apparatus of Figure 1, the ratio of the heat liberated in the regeneration zone to the heat required in the conversion zone for hydrocarbon conversion may also be varied. Thus by proper adjustment of the rate of cyclic flow of the solid material, a balanced operation may be obtained wherein the heat released in vapors at this location.

the regeneration zone is substantially equal to' that required for hydrocarbon conversion in the conversion zone, thereby providing a cyclic conversion system wherein a stable range of contact material temperatures may be continuously maintained throughout the system without the requirement for any auxiliary external cooling system at all. This method of operation should not be confused with that method of cyclic operation wherein the cyclic rate of flow of solid material is regulated so as to limit the amount of contaminant deposited on the solid material passing through the conversion zone below that which upon subsequent combustion in the regeneration none would raise the solid material temperature to heat damaging levels unless external heat removing means are provided within said regeneration zone. This latter method is entirely different from the one contemplated herein and is the subject of my United States Patent Number 2,418,679 issued April 8, 1947.

As has been shown, the cooling tubes 49 and auxiliary cooling equipment may be entirely eliminated by the method of operation hereinabove disclosed. Since, however, the size of this cooling system is very small and sinceits use in conjunction with the above method of operation will add increased flexibility to theoperation of the apparatus of this invention, such an auxiliary equipment may preferably be provided. It should be added that when the apparatus is used for applications wherein the heat required for conversion is greater than that liberated in the regeneration zone,-the tubes 49 may then be used for the purpose of adding heat to the system, in which case a heat transfer fluid. externally heated, would be circulated through the tubes 49.

Turningnow to Figure 2, we find a plan view taken at line 2-2 of Figure 1, showing the vessel shell It, the regenerator tubes IS, the partition II, from which said tubes depend and the conveyor casings l3, I4 and it. It should be understood that further conveyors may be provided within the vessel, if desired, in addition to those shown. The use of vessels of other cross-sectional shape is also within the scope of this invention. Moreover, it is not entirely necessary that the lower end of the vessel It be reduced, as shown, into a bottom section l2.

Turning now to Figure 3, we find an enlarged view of one of the vapor distributing devices used in partition I! of Figure 1. In Figure 3, 42 is a part of said partition, 43 is a truncated hollow cone covering one of the holes through said partition and 44 is a pipe dependent from the top of said truncated cone. The pipe 44 being smaller in diameter than the hole in the partition 42 provides an annular space 19 for vapor flow. Louvered openings 80 are provided in the truncated cone, said openings being such as to permit flow of vapors therethrough into the solid material in the conversion zone while substantially louvers 80 into the conversion zone. Such an arrangement prevents interference with the solid flow through pipes 44 that might otherwise occur, due to the high velocity of the hydrocarbon It will be seen from Figure 2, that due to the great number of pipes it which extend through the partition 42, the use of vapor distributing channels which extend across the vessel is impossible. Thus the arrangement, above described, provides a simple, sturdy and eflicient means for distributing inlet vapors or for collecting outlet vapors in an apparatus of this type. It should be noted that other mem-- bers, such as truncated pyramids, may be substituted for the truncated cones, shown therein.

Turning now to Figure 4, we find a section of the conveyor casing l3, through which extends the screw conveyor drive shaft 82. It will be seen that the screw conveyor differs from conventional types in that the spiral flange 65 shown in Figure l is not the usual spiral fiange but is composed of a spiral flange which extends horizontally substantially short of the casing wall, and attached along the flange 85 is the spring metal tip 86 which presses against the casing wall. In ordinary screw conveyors a relatively heavy spiral flange would extend horizontally to within a short distance of the casing wall thereby leaving a space between the casing wall and the edge of flange which would become filled with the particle form solid material being conveyed. Such material would be crushed in this space as it passed through the conveyor, thereby resulting in considerable and undesirable breakdown in the size thereof. In the construction shown herein, the spring metal tip is made of very thin metal so as to prevent undue friction in the conveyor operation. On the other hand, by pressing against the conveyor wall, it eliminates the space between the edge of the conveyor flange and the conveyor wall, thereby eliminating the crushing of the solid material. This is of considerable importance in cyclic conversion systems of the type herein described, wherein it is very desirable, both from a stand! point of economics and of proper operation in theentire cyclic system to limit the solid material attrition to a minimum.- It will be understood that while the hereinabove described conveyor is a preferable type for use in the apparatus of this invention, other conveyors of other types may be used provided that such conveyors are of a type which will convey the solid material upwardly as a substantially compact column, thereby providing highly important vapor seal legs.

It may be seen from the above description of this invention that by elimination of all or at least the major part of the auxiliary heat removal apparatus and by the incorporation of substantially the entire cyclic conversion apparatus within a single vessel, a relatively simple, compact and economical cyclic conversion system has been provided which may be constructed in sizes suitable for small refineries at costs substantially below those of conventional systems. Moreover, by direct supply of the heat required for hydrocarbon conversion from the regeneration zone. the necessity for providing the heat for reaction to the conversion zone by means of heat transfer circulation systems or by substantially assembled in the fabrication shops before shipment to the small refineries. Such units may then be easily and quickly installed in the field with a minimum of cost and trouble. The small amount of spaceoccupied by such apparatus will permit its installation in small refineries between existing thermal cracking furnaces and product fractionation recovery equipment. thereby permitting the use of the existing equipment for stock preparation for the new apparatus and for recovery of product therefrom. Due to the large amount of space required by conventional cyclic conversion systems, the tie-in of such systems with existing thermal cracking equipment has not been heretofore feasible in most instances.

The proper design of the apparatus of this invention is dependent upon a number of variables which are inherent in any particular application. Such variables are the nature of the hydrocarbon stock and the nature of its conversion contemplated. the general type and nature of the particle form contact material, the possible rate 'of the specific regeneration and conversion reactions involved and the heat transfer characteristics of the solid material vapor system involved. Generally. in order to provide proper contact material temperature control within the regeneration zone, in the case of clay-type catalyst particles used in hydrocarbon conversion systems, the maximum distance of a solid material particle from a heat transfer surface (1. e., walls of the regeneration vessel) should be less than two inches and preferably of the order of one inch. In. relation to the rates of gas or vapor flow through the substantially compact beds or columns of solid material within the reaction and regeneration zones, it maybe said that sufilcient cross-section for gas flow should be provided to limit the pressure drops due to the fiow' thereof through the solid material below that which would cause disruption or boiling of said solid material. Such pressure drop data for the particular gases or vaors and particle form solid to be used may be readily obtained by simple experiments with these materials or may be calculated from existing data. Similar provision of sufiicient crosssection for gas flow should be provided at the locations of disengagement of eiiluent gas from the solid material within the apparatus.

It should be understood that the invention is not limited to operations involving hydrocarbon conversion but may be applied to other operations involving endothermic and exothermic reactions in the presence of moving particle form solid material. It should be further understood that the foregoing illustrations of the construction, operation and application of this invention are merely exemplary in character and are in no way intended to limit the scope of this invention.

I claim:

1. A method for the conversion of high boiling vaporous hydrocarbons to lower boiling gaseous hydrocarbons in the presence of a moving particle-form contact material which comprises: maintaining a substantially compact column of particle form contact material within an upper portion of a confined conversion zone and a substantially compact bed of said contactmaterial within the lower portion of said conversion zone spaced below the bottom of said column. supplying fresh contact material to the upper end of said column at a temperature suitable for said hydrocarbon conversion, passing lised contact material from near the bottom of said column as a plurality of horizontally spaced apart. confined, compact substantially vertical streams onto the surface of said bed. whereby a single as space is provided in said conversion zone around said confined streams. withdrawing contact material from the bottom of said bed so as to cause downward flow of contact material in said column and said bed, establishing a region of substantially static contact material in a lower portion of said column, introducing heated bydrocarbon vapors into the upper section of said column and passing said vapors downwardly within said column to efiect conversion of said hydrocarbons to lower boiling gaseous hydrocarbon products. disengaging said gaseous products from the contact material in said static region and flowing the disengaged gas into a plurality of spaced apart gas collecting spaces in gas flow communication with said column, passing the collected gaseous products in confined streams from said gas collecting spaces -to said single gas space above said bed and withdrawing said gaseous conversion products from said single gas space.

2. In a process wherein fiuid hydrocarbons are converted to lower boiling gaseous hydrocarbons in the presence of a substantially compact column of downwardly moving particles in a confined conversion zone, the method for withdrawing gaseous products from said column without substantial entrainment of contact material particles which comprises: collecting gaseous products from said column at locations therein wherein the contact material flow is substantially static into a plurality of collecting spaces within said column said spaces being shielded from gravity flow of said contact material and distributed substantially uniformly across the horizontal cross-sectional area of said column, passing gaseous products and any entrained contact material downwardly from each of said gas collecting spaces as a separate confined stream into a single settling space maintained in said columnbelow said gas collecting spaces, said settling space being sufliciently large to permit settling of entrained contact material in said streams from said gas spaces onto the surface of the contact material column at the lower end i of said settling space and withdrawing gaseous products from said settling space.

3. A method for conversion of fluid hydrocarbons in the presence of a particle-form contact material which comprises: maintaining a substantially compact column of contact material particles within a confined conversion zone. withdrawing used contact material from the lower section of said column and supplying contact material to the upper end of said column at a suitable hydrocarbon conversion tempera ture, introducing fluid hydrocarbon reactant to the upper section of said column, passing said hydrocarbon reactant downwardly in said column to eifect its conversion to vaporous hydrocarbon products, diseng gin the vaporous products from said column at locations in the lower portion thereof where the contact material is substantially static as regards flow and collecting said products into a plurality of horizontally spaced apart gas collecting spaces from which gravity flow of the contactmaterial is excluded. diverting and directing the contact material now in said lower portion oi. said column to subdivide the contact material into a plurality of horizonamazes tally spaced apart confined streams of contact material extending downwardly through a, v tical section of said column and delivering onto a continuation of said column at a level substantially below said gas collecting spaces, said streams being of substantially smaller horizontal dimensions in all directions than said column, whereby there is established a single gas space in said column below said collecting spaces and around said confined stream of contact material which single space is open on its lower end to said continuation of said column and is substantially larger than said gas collecting spaces, passing the collected vaporous products from each of said collecting spaces as a confined stream downwardly into said single gas space to effect additional separation of contact material from said products and finally withdrawing said vaporous hydrocarbon products from said single gas space.

4. A method for conversion of fiuid hydrocarbons in the presence of a particle form contact material which comprises: passing said contact material downwardly through an upper portion of a confined zone as a substantially compact column at a temperature suitable for said hydrocarbon conversion, subdividing the contact material fiow in a lower portion of said zone into a plurality of confined, horizontally spaced compact streams extending downwardly through a vertical portion of said zone and delivering onto a continuation of said column in a still lower portion of said zone whereby a single gas space is provided around said streams and above said continuation of said column. maintaining a region of relatively stagnant contact material as regards its flow below the level of the upper ends of said compact streams but above said single gas space, withdrawing contact material from the lower end of said confined zone, introducing fluid hydrocarbon reactant into the upper section of said confined zone and passing it downwardly through said column to effect its conversion to gasiform hydrocarbon products, collecting said gasiform products in a plurality of horizontally spaced gas spaces maintained in said region of stagnant contact material, passing the collected products from each of said gas spaces as a confined stream downwardly into said single gas space to effect a final separation of contact material particles from the gasiform products and withdrawing the gasiform products from said single gas space.

5. In a process wherein .a gaseous material is contacted in a confined zone with a substantially compact bed ofcontact material particles moving downwardly through said confined zone the improved method of maintaining gas flow between said bed within said zone and a location outside of said zone which method comprises: maintaining a stagnant region in said bed wherein the contact material remains substantially stationary, establishing a single gas space in said bed below said stagnant region, which gas space is open to a continuation of said bed therebelow, effecting contact material flow from a level in said bed above said stagnant region onto said continuation of said bed while excluding the contact material fiow from said single gas space, establishing a plurality of horizontally spaced apart gas spaces within said stagnant region which gas spaces are substantially smaller than said single space and are in gas flow communication with said bed, maintaining gas flow between said bed and said smaller gas spaces, passing gas as a separate stream from which gravity flow of the bed is excluded between each of said smaller gas spaces and said single gas space and maintaining gas flow between said single gas space and a location outside of said confined zone.

6. A method for contacting gases with moving particle form solids comprising, maintaining two superposed confined beds of. said solid material in two superposed confined zones. supplying particle form solids to the upper end of the upper bed, withdrawing solids from a level shortly above the bottom of said upper bed as a plurality of horizontally spaced, substantially vertical, confined, compact streams delivering onto the lower bed at a level below the upper end of the lower zone, whereby there is provided a stagnant layer of solids along the bottom of the upper zone and there is provided a single gas space above the bed in said lower zone, withdrawing solids from the lower end of said lower zone, maintaining gas flow between the upper section of said upper zone and a location outside of said confined zones, establishing a plurality of spaced apart gas spaces within said stagnant layer in said upper zone, said gas spaces being substantially smaller in size than said single gas space in said lower zone and being in gas flow communication with said bed in said upper zone, passing gas in a confined stream between each or said gas spaces in said stagnant layer and said single gas space in said lower zone, and maintaining gas flow between said single gas space and a second'location outside of said confined zones.

'7. In a gas-solid contacting vessel adapted for confining a substantially compact column of particle-form solid material therein an improved means for withdrawal of gas from said column in said vessel which comprises: a substantially horizontal partition extending across said vessel at a level which is intermediate the ends of said vessel, a plurality of uniformly spaced inverted gas collecting hoods positioned on said partition, said hoods having apertures in their sides adapted to permit entry of gas while substantially excluding solid particle flow, conduit means for solid flow passing through said partition from a level above that of the highest apertures in said hoods to a level substantially below said partition, an opening for gas flow in said partition below eachof said hoods, and means to withdraw gas from said vessel at a level below said partition but above the lower extremity of said conduit means.

8. A gas solid contacting apparatus which comprises in combination, a substantially vertical vessel, means to supply contact material to the upper end of said vessel, means to withdraw contact material from the lower end of said vessel, a gas passage conduit connected into the upper section of said vessel from the exterior, a substantially horizontal partition across the lower section of said vessel, a plurality of uniformly spaced apart inverted gas handling hoods positioned on said partition, said hoods having louvred sides adapted to admit gas flow but to exclude substantial solid material flow, at least one aperture for for confining a substantially compact column of particle-form solid material therein an improved means for passage of gas between said column within said vessel and a location out- 1'.side of said vessel which comprises: a partition extending across said vessel at a level substantially below the upper end of said vessel and substantially above its lower end, a plurality of spaced, inverted cups positioned within said vessel on said partition, said cups being adapted to permit flow of gas into their interiors while preventing gravitational flow of solid material thereinto, conduit means for passage of solid material from a level corresponding approximately to that of the tops of said cups to a level a spaced distance therebelow, so as to provide a gas space immediately under said partition, means defining a confined passage for gas flow between the interior ofeach of said inverted cups and the gas space under said partition and passage defining means communicating said gas space with the exterior of said vessel.

' 10. In a gas-solid contacting vessel adapted for confining a substantially compact column of particle-form solid material therein an improved means for distribution of gas into said column of solid material which comprises: a substantially horizontal partition extending across said vessel at a-level which is under the surface of the said solid material column therein, said partition having a plurality of uniformly spaced holes therein, a

' truncated upwardly tapered shell covering each of said holes, said gshells having louvered sides of such construction as to permit free gas flow there-through while substantially preventing gravitational flow of said solid material therethrough, a short pipe dependent from the top of each truncated shell and extending downwardly through the hole in said partition and terminating below said partition each of said pipes having an external cross-sectional area substantially less than that of said holes, said pipes providing a passage-for said solid material through said partition and providing a substantially solid-free gas space immediately below said partition in free gaseous communication with the louvres in said truncated shells, means to admit gas to said gas space.

11. An apparatus for conversion of hydrocarbons in the presence of moving particle form cataylst and for regeneration of said catalyst comprising: an elongated vertical vessel closed on both ends, a partition arrangement within said vessel defining separate vertical, elongated conversion and regeneration zones in heat transfer relationship with,each other, said zones being suitable for confining therein substantially compact columns of said catalyst, said partition ar-- rangement also defining a separate accumulation zone for said cataylst below and in communication with said conversion zone and a separate accumulation zone for said catalyst below and in communication with said regeneration zone, at least one enclosed mechanical conveyor for con.- veying said catalyst upwardly through said vessel between said accumulation zone below said regeneration zone and the upper section of said conversion zone, at least one enclosed mechanical conveyor for conveying said catalyst upwardly through said vessel between said accumulation zone below said conversion zone and the upper section of said regeneration zone, said conveyors being of such type as will move said catalyst upwardly as substantiallycontinuous compact columns, means to maintain inert gaseous atmosphere substantially throughout the length of said conveyors, inlet means to admit hydrocarbon vapors at controlled temperatures to said conversion zone said inlet means comprising, a horizontal partition extending across said conversion zone within said vessel, said partition being positioned near the lower end of said conversion zone and said partition having a plurality of uniformly spaced holes therein, a truncated hollow pyramid covering each of said holes, said pyramids having louvered sides of such construction as to permit free gas flow therethrough while substantially preventing gravitational fiow of said solid material therethrough, a short pipe dependent from the top of each truncated pyramid and extending downwardly through the hole in said partition and terminating below said partition, each of said pipes having an external cross-sectional area substantially less than that of said holes, saidpipes providing a passage for said solid material through said partition and providing a substantially solid-free gas space immediately below said partition in free gaseous communication with the louvers in said truncated pyramids, means to admit hydrocarbon vapor to said gas space, outlet means for vapor products from said conversion zone, said outlet means being remotely positioned from said inlet means, inlet means to admit regeneration gas to said regeneration zone and outlet means for gases therefrom, said regeneration gas outlet means being remotely positioned from said regeneration gas inlet means.

12. An apparatus for conversion of hydrocarbons in the presence of moving particle form catalyst and for regeneration of said catalyst comprising: an elongated vertical vessel closed on'both ends, a partition arrangement within said vessel defining separate vertical, elongated conversion and regeneration zones in heat transfer relationship with each other, said zones being suitable for confining therein substantially compact columns of said catalyst, said partition arrangement also defining a separate accumulation zone for said catalyst below and in communication with said conversion zone and a separate accumulation zone for said catalyst below and in communication with said regeneration zone, at least one enclosed mechanical conveyor for conveying said catalyst upwardly through said vessel between said accumulation zone below said regeneration zone and the upper section of said conversion zone, at least one enclosed mechanical conveyor for conveying said catalyst upwardly through said vessel between said accumulation zone below said conversion zone and the upper section of said regeneration zone, said conveyors being of such type as will move said catalyst upwardly as substantially continuous compact columns, means to maintain inert gaseous atmosphere substantially throughout the length of said conveyors, a horizontal partition extending across said conversion zone within said vessel, said partition being positioned near the lower end of said conversion zone and said partition having a plurality of uniformly spaced holes therein, a truncated hollow cone covering each of said holes, said cones having louvered sides of such con-" struction as to permit free gas flow therethrough while substantially preventing gravitational fiow of said solid material therethrough, a short pipe dependent from the top of each truncated cone and extending downwardly throughthe hole in said partition and terminating below said partition, each of said pipes having an external crosssectional area substantially less than that of said holes, said pipes providing a passage for said solid material through said partition and providing a substantially solid-free gas space immediately below said partition in free gaseous communication with the louvers in said truncated cones, means to admit hydrocarbon vapor to said gas space, outlet means for vapor products from said conversion zone, said outlet means being remotely positioned from said inlet means, inlet means to admit regeneration gas to said regeneration zone and outlet means for gases therefrom, said regeneration gas outlet means being remotely positioned from said regeneration gas inlet means.

13. An apparatus for conversion of hydrocarbons in the presence of moving particle form catalyst and for regeneration of said catalyst comprising: an elongated vertical vessel closed on both ends, a partition arrangement within said vessel defining separate vertical, elongated conversion and regeneration zones in heat transfer relationship with each other, said zones being suitable for confining therein substantially compact columns of said catalyst, said partition arrangement also defining a separate accumulation zone for said catalyst below and in communicolumns, means to maintain inert gaseous atmosphere substantially throughout the length of said conveyors, a horizontal partition extending across said conversion zone within said vessel, said partition being positioned near the lower end of said conversion zone and said partition having a plurality of uniformly spaced holes therein, a truncated upwardly tapered shell covering each of said holes, said shells having louvered sides of such construction as to permit free gas flow therethrough while substantially preventing gravitational flow of said solid material therethrough, a short pipe dependent from the top of each truncated shell and extending downwardly through the hole in said partition and terminating below said partition each of said pipes having an external cross-sectional area substantially less than that of said holes, said pipes providing a passage for said solid material through said partition and providing a substantially solid-free gas space immediately below said partition in free gaseous communication with the louvres in said truncated shells, means to admit hydrocarbon vapor to said gas space, outlet means for vapor products from said conversion zone, said outlet means being remotely positioned from said inlet means, inlet means to admit regeneration gas to said regeneration zone and outlet means for gases therefrom, said regeneration gas outlet means being remotely positioned from said regeneration gas inlet means.

ERNEST UTTERBACK.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

